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Designation: D4385 − 10

StandardPractice for
Classifying Visual Defects in Thermosetting Reinforced
Plastic Pultruded Products1
This standard is issued under the fixed designation D4385; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.

1. Scope* 3.3 Punchability—Products not exceeding 4.7 mm (0.185

1.1 This practice covers acceptance criteria for visual ac- in.) thickness, having Reinforcement Material G and Rein-
ceptance of thermosetting reinforced plastic pultruded rods, forcement Type M in accordance with Practice D3647, shall be
bars, shapes, and sheets. capable of being punched, drilled, and riveted without causing
splitting or delamination when good commercial practices are
1.2 This practice presents definitions of possible defects to employed (for example, proper backup, adequate hole spacing,
serve as a guide for contracts, drawings, product specifications, etc.).
and final inspection.
3.4 Critical Areas—Areas in which the presence of imper-
1.3 This practice also categorizes different inspection re- fections is considered to be detrimental to the proper function
quirements for the three of four grades of product quality of the part shall be designated as critical areas. The areas of a
identified herein. product that are critical structurally, aerodynamically,
1.4 This standard does not purport to address all of the electrically, or for some other purpose shall be uniform and in
safety concerns, if any, associated with its use. It is the accordance with the quality levels of Table 1 as stated on the
responsibility of the user of this standard to establish appro- product drawing. Critical areas may be designated on the
priate safety and health practices and determine the applica- product drawing by one of the following methods:
bility of regulatory limitations prior to use. 3.4.1 Encircle critical areas,
NOTE 1—There is no known ISO equivalent to this standard. 3.4.2 Cross-hatch areas to designate areas of various levels,
or
2. Referenced Documents 3.4.3 Word description of the critical area(s).
2.1 ASTM Standards:2
3.5 Allowable Defects—Defects that by nature, number, or
D3647 Practice for Classifying Reinforced Plastic Pultruded
frequency of occurrence do not affect the serviceability of the
Shapes According to Composition
product. These allowable defects shall be fully described as to
D3917 Specification for Dimensional Tolerance of Thermo-
type, size, number, extent allowed, and spacing. The appropri-
setting Glass-Reinforced Plastic Pultruded Shapes
ate acceptance level (see Table 1) for defects in these areas
3. Acceptance Criteria must be specified. Defects in excess of those listed as allowable
in the product specifications, drawings, or contracts for the
3.1 The method and frequency of sampling and the quality product shall be cause for rejection.
level shall be agreed upon between the purchaser and the seller.
3.6 Acceptable Defects—Unless otherwise specified, the
3.2 Dimensions and Tolerances—Pultruded shapes shall be
following defects shall be acceptable in all instances:
inspected for conformance with dimensions and tolerances
3.6.1 Shrink-Mark—A dimple-like depression on the sur-
specified on the product drawing or by D3917. Products with
face of a pultruded shape where it has retracted from the
any dimensions exceeding the specified limits shall be rejected.
pultrusion die, and which has well-rounded edges. A shrink-
mark generally occurs on one surface of a part where there is
1
This practice is under the jurisdiction of ASTM Committee D20 on Plastics and a boss, flange, rib, or other heavy section on the opposite
is the direct responsibility of Subcommittee D20.18 on Reinforced Thermosetting surface. The shrink-mark may be caused by the difference in
Plastics.
Current edition approved April 1, 2010. Published May 2010. Originally
total shrinkage when there is a sudden change in section along
approved in 1984. Last previous edition approved in 2008 as D4385 - 08. DOI: the surface of the part.
10.1520/D4385-10.
2
3.6.2 Resin Voids—Applicable to a number of mat- and
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
fabric-type reinforcement systems, particularly continuous
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on strand mat used without a surfacing material or woven fabrics.
the ASTM website. The resin voids appear as multiple surface interruptions that

*A Summary of Changes section appears at the end of this standard

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 D4385 − 10
conform to the pattern of the cloth weave or the continuous concerned with those defects described by the product
strand mat fiber distribution. This is usually due to an insuffi- specifications, drawings, or contracts for the pultruded prod-
cient flow or shrinkage of the resin that fails to fill all of the ucts. If none of these first three levels (Levels I, II, or III) is
interstices of the fabric or mat reinforcement. These defects considered applicable, the level shall be Level IV, and allow-
occur only on the surface layer of resin in contact with the able defects must be specified on the product specification or
pultrusion die or mold. drawing including the criteria for acceptance. Any excess of
3.6.2.1 Pultrusions intended for chemical corrosion environ- defects, as specified under the required level, shall be cause for
ments with pH below 5, or over 9, or for immersion rejection. Unless otherwise specified, the dimensions in this
applications, require a synthetic surface veil to ensure adequate practice are surface dimensions.
resin coverage. Any resin voids shall be repaired.
4.2 Acceptance Level I—Presence of any defects in excess
3.7 Repairable Defects—Repairable defects are those that of those listed in Table 1, Level I, shall be cause for rejection.
can be repaired without affecting the serviceability of the
product unless otherwise specifically prohibited on product 4.3 Acceptance Level II—Presence of defects in excess of
specifications, drawings, or contracts. The specific repairable those listed in Table 1, Level II, shall be cause for rejection, if
defects include blister, chips, die-parting line, gouges, defect is not repairable.
grooving, intermittent disfigurement, scale, scuffing, sluffing, 4.4 Acceptance Level III—Presence of defects in excess of
stop mark, wire brush surface, and resin voids (see 3.6.2). The those listed in Table 1, Level III, shall be cause for rejection, if
repaired product must conform to the limits of Table 1. Other defect is not repairable.
defects may be repaired by mutual consent of the customer and
the pultruder. Methods of repair shall be agreed upon between 4.5 Acceptance Level IV—Any defect not specifically de-
the purchaser and the seller and shall be fully described by the fined by size or shape in Levels I, II, or III that falls into a
product specification, drawings, or contracts. category between Levels I, II, and III or is beyond Level III and
is considered acceptable, shall be designated as Level IV and
4. Acceptance Levels shall be specified on the product specification or drawing. Any
4.1 Visual Inspection—Each sample selected in accordance such defect shall be fully described as to size, shape, number,
with 3.1 shall be checked visually without the aid of magnifi- extend, and spacing on the product drawing, product
cation. Defects shall be classified as to type and level, as shown specification, or contracts for the products.
in Table 1. The quality level shall be determined by reference
to the product specification or drawing for the applicable 5. Keywords
acceptance level for allowable defects. The inspection shall be 5.1 pultrusion; structural shapes; visual

TABLE 1 Acceptance Criteria

Visual Acceptance Levels
Name Definition
Level I Level II Level III
Black Marking Black smudges on the surface of the None Permitted if not over 12 mm wide or 20 Permitted if not over 25 mm and all
pultruded product that cannot be cm long or more than 4 marks per 3 m product test requirements are satisfied
removed by cleaning, scrubbing, or of length.
wiping with solvent.

Blister A rounded elevation of the pultruded None Permitted if not on the exterior surfacePermitted if formed between surfacing
surface with boundaries that may be formed between the surfacing veil and layer and balance of laminate, width is
more or less sharply defined. first layer of reinforcement. And less no greater than 40 % of surface width
than 15 mm in diameter. No more than (but 7 cm max) and length is not over
one per 3 m in length. 20 cm. No more than 2 per 3 m of
NOTE—The rounded elevation length. Blisters less than 19 mm in
somewhat resembles in shape a blister diameter are permitted on interior
on the surface of human skin. surfaces that are bonded. A popcorn
blister (less than 1.5 mm in diameter
and .25 mm high) is permitted.
Blisters may exist within the pultrusion Product must meet test requirements and not exceed dimensional tolerances.
as a hollow delaminated area (gas-
filled) under a raised portion of the Repair if limits exceeded.
surface.

Blooming, Undercure A dull and bleached surface color that None None None
is evident in pultruded material not
exposed to the weather.

Burn A discoloration, distortion, or None None None

destruction of the pultruded surface as
a result of thermal decomposition.

Chips (Gouges) Minor damage to the pultruded surface None Not over 6 mm long or wide or 0.64 Not over 10 mm wide or long or 0.64
that removes material but does not mm deep. Not more than 4 per 3 m of mm deep. Not more than 5 per 3 m of
cause a crack or craze. length. Repair if limits exceeded. length. Repair if limits exceeded.

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 D4385 − 10
TABLE 1 Continued
Visual Acceptance Levels
Name Definition
Level I Level II Level III
Crack A visual separation that penetrates None None None
down from the pultruded surface to the
equivalent of one full ply or more
reinforcement (0.5 mm). See internal
shrinkage cracks.

Crater A small, shallow pultrusion surface None Not over 1 mm in diameter and 0.64 Acceptable if it does not reduce the
imperfection. mm deep. Maximum of 5 per 64.5 cm part thickness below the minimum
of area and no more than 1 such area specification.
per 0.3 m of product.
Not permitted in same area of unrepaired chips and gouges.

Craze Multiple fine separation cracks at the None Not over 9 mm long or 0.4 mm wide, Can be over the entire length of the
pultruded surface not penetrating into not more than 12 per 3 m of length. part.
the reinforcement nor to the equivalent
depth of one ply of reinforcement.
NOTE—This condition is usually due to
resin shrinkage during cure in resin-
rich areas.

Delamination The separation of two or more layers None None None

or plies of reinforcing material within a
pultrusion causing a localized
thickness change exceeding 0.13 mm
(0.005 in.)

Die Parting Line A lengthwise flash or depression on The line projection caused by the die- The line projection caused by the die
the surface of a pultruded plastic part. parting line shall not extend past the parting line shall not extend past the
The die parting line is not part of the product’s surface by more than 0.20 product’s surface by more than 0.30
dimensional tolerance. mm for shapes less than 3.1 cm wide mm. It shall not create a sharp feeling
and 0.3 mm for shapes greater than or have loose fibers. Repair if limits are
3.1 cm wide. It shall not create a sharp exceeded.
feeling or have loose fibers. Repair if
limits exceeded.
NOTE—The die-parting line is
associated with the area where
separate pieces of the die join together
to form the cavity.

Discoloration A streak of other pattern on the surface None Spots of any color not over 12 mm in Spots of any color not over 19 mm in
that causes a noticeable change of diameter or 4 per 3 m of length are diameter or 8 per 3 m of length are
color from the rest of the pultruded permitted. Streaks or longitudinal permitted. Streaks or longitudinal
surface. stains permitted if not over 12 mm stains permitted if not over 19 mm
wide, 20 cm long, or more than 4 per 3 wide, 25 cm long, or more than 6 per 3
m of length. m of length. Continuous discolorations
caused by a veil overlap are permitted.
Mat discolorations are not rejectable

Dry Fiber (Lack of Resin A condition in which fibers are not fully None If internal, permitted if product meets test requirements. If on the surface, see
Fillout) encapsulated by resin during blooming, fiber.
pultrusion.
NOTE—This does not include
surfacing veil.

Dullness A lack of normal pultruded surface None Permitted unless caused by insufficient cure.
gloss or shine.
NOTE—This condition can be caused
by insufficient cure locally or in large
areas, resulting in the dull band
created on a pultruded part within the
die when the pultrusion process is
interrupted briefly (see stop mark).

Exposed Rovings The underlying layer of roving not None Permitted if surfacing material covers Permitted if surfacing material covers
covered by surface material in a all but 9.5 mm from each free edge but all but 11 mm from each free edge, but
pultrusion. not to exceed 40 % of the width of the not to exceed 40 % of the width of the
surface being inspected or 25 % of the surface being inspected or 30 % of the
perimeter of a round product. perimeter of a round product. Carrier
rovings can be used on the surface of
a tube without rejection. Connection
areas can have exposed rovings.
The exposed underlayment may be present intermittently along an entire length. All
reinforcing fibers shall be encapsulated with resin.

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 D4385 − 10
TABLE 1 Continued
Visual Acceptance Levels
Name Definition
Level I Level II Level III
Fiber Bridging Reinforcing fiber material that is found None Permitted if reinforcing fibers are encapsulated by resin, no corner cracks exist,
bridging across on an inside radius of and there is no evidence of delamination.
a pultruded shape.
NOTE—This condition is caused by
shrinkage stresses around such a
radius during cure.

Fiber Prominence A visible and measurable pattern of the None Permitted if reinforcing material is encapsulated by resin.
reinforcing material on the surface of a
pultruded plastic part.

Folded Reinforcement An unintentional or unspecified None Not permitted when fold results in 3 or Permitted if test requirements are met.
misalignment of mat or fabric more plies affected and a Other visual requirements caused by
reinforcing material in relation to the reinforcement-rich area. mat folds must satisfy the specification.
contour of a pultruded section.
NOTE—Such folds may or may not
affect the surface appearance of the
pultrusion and are visible in a cut cross
section of the product.

Fracture Cracks, crazing, or delamination, or a None None None

combination thereof, resulting from
physical damage to the pultrusion.

Grooving Long narrow grooves or depressions in None Permitted if material thickness Permitted if material thickness
a surface of a pultrusion parallel to its reduction is not over 10 % and groove reduction is not over 10 % and the
length. width is 3 mm or less. May be groove width is 3 mm or less. May be
continuous in a length. Grooves on continuous in length. Grooves on
opposing surfaces are not permitted. opposing surfaces are not permitted.
Must satisfy dimensional requirements. Must satisfy dimensional and
mechanical requirements.

Inclusion Any foreign matter or particles that are None No metallic inclusion is permitted if Permitted if product meets test
either encapsulated or imbedded in the product is for electrical use. For requirements. None in excess of 12
pultrusion. nonelectrical application, none in mm in diameter or no more than 6 per
excess of 9 mm in diameter. No 3 m of length. No inclusion should
inclusion shall create a surface blemish create a surface blemish above the
above the resin. Not over 4 per 3 m of resin.
length.

Insufficient Cure A pultrusion abnormally created by lack None None Repair by postcure if test requirements
of, or incomplete, crosslinking of the can be met and surface appearance is
resin. acceptable.
NOTE—This condition can usually be
detected by dull surface appearance,
low Barcol hardness, and low physical
properties. Thick sections, cured from
the outside in, can reveal insufficient
cure in the center of the section even
though completely cured on the
surface. This condition can be caused
by insufficient die temperature,
improper catalyst, or pulling too fast for
the die temperature.

Internal Shrinkage Cracks Longitudinal cracks in the pultrusion None Permitted except for rod and bar of all Permitted without numerical limit if the
that are found within areas of roving roving reinforcement, if the crack does crack does not reach the surface of the
reinforcement and terminate in the off- not reach the surface of the product product and the product meets test
axis reinforcement.. and product meets test requirements. requirements.
NOTE—This condition is caused by
shrinkage strains during cure that
appear in the roving portion of the
pultrusion where transverse strength is
low.

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 D4385 − 10
TABLE 1 Continued
Visual Acceptance Levels
Name Definition
Level I Level II Level III
Porosity, Internal (Void) The presence of numerous pits or pin- None For material thicknesses below 9 mm, For material thicknesses below 9 mm,
holes beneath the pultruded surface, no more than 10 pits or pinholes per no more than 20 pits or pinholes per
usually observable only in a cut cross 64.5 cm2 of cross section. Materials 9 64.5 cm2 of cross section. For
section. mm and over in thickness, no more materials 9 mm and over in thickness,
than 30 pits per 64.5 cm2 of cross no more than 60 pits or pinholes per
section. Sum of pinhole porosity area 64.5 cm2 of cross section. Sum of
and void area shall be no more than pinhole porosity area and void area
4 % of cross-sectional area. shall be no more than 8 % of cross-
sectional area. Shapes exceeding the
limits can be accepted if the properties
including water absorption are
satisfied.

Porosity, Surface (Void) The presence of numerous visible pits None Permitted if pits are less than 0.4 mm Permitted if pits are less than 0.8 mm
or pinholes at or near the pultruded in diameter and 0.38 mm deep. in diameter and 0.51 mm deep.
surface. Maximum of 5 pits per 64.5 cm2 of Maximum of 10 pits per 64.5 cm2 of
area and no more than one such area area and no more than 4 % of cross-
per 0.3 m of product. Surface porosity sectional area per 0.3 m of product.
is permitted if the customer specifies Surface porosity is permitted if the
that no surfacing veil is to be used. customer specifies that no surfacing
veil is to be used.

Reinforcement Distortion Knotted, tangled, widely spaced, or None Permitted if product meets test requirements.
otherwise abnormal but local
irregularities in reinforcement
distribution throughout the pultruded
cross section.
NOTE—This condition usually causes
noticeable changes in the local
reinforcement content with crushing of
the reinforcement or resin-richness in
isolated areas.

Resin-Rich Area An area of the pultrusion that lacks None Permitted if product meets test requirements.
sufficient reinforcement.
NOTE—The fiber pattern may not be
visible.

Roving Knot A knotted or entangled section of None Permitted if encapsulated with resin and product meets test requirements and
roving found in a pultrusion. dimensional tolerances.
NOTE—Such a knot may cause high
fiber concentration locally and may or
may not be visible as a white or light
spot on the surface of the section.

Saw Burn Blackening or carbonization of a cut None Permitted if product meets test requirements.
surface of a pultruded section.

Scale A condition wherein resin plates or None Permitted if removal does not expose dry fibers and dimensional tolerances are
particles are on the surface of a met. Repair of exposed fiber permitted if dimensional tolerances are met.
pultrusion.
NOTE—Scales can often be readily
removed, sometimes leaving surface
voids or depressions.

Scuffing Long white scrape marks on the None Permitted if not over 12 mm wide or 20 Permitted if not over 19 mm wide or
surface of the pultrusion. cm long and not over 4 such marks 30.5 cm long and not over 5 such
NOTE—This condition usually results per 3 m of length. On inside radius, marks per 3 m of length. On inside
from mechanical scraping or scratching permitted if not over 1.5 mm wide or radius, permitted if not over 3 mm wide
of the pultrusion in the machine or in 76 mm long even if they appear or 15 cm long even if they appear
handling it afterwards. intermittently along each length. Repair intermittently along each length. Repair
if limits exceeded. if limits exceeded.

Sluffing A condition wherein scales peel off or None Permitted if sharp feeling is not created and dimensional tolerances are met.
become loose, either partially or Repair permitted if dimensional tolerances are met.
entirely, from the pultrusion.
NOTE—This term is applied to an
occurrence during the pultrusion
process and is not to be confused with
scraping, prying, or physically
removing the scale from the pultrusion.
Sluffing is sometimes spelled
sloughing.

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 D4385 − 10
TABLE 1 Continued
Visual Acceptance Levels
Name Definition
Level I Level II Level III
Stop Mark A band, either dull or glossy, on the None Permitted unless other defects (such Permitted unless unrepairable defects
surface, approximately 12 to 100 mm as scale, craters, chips, and gouges) result. Repair all other resulting
long and extending around the result. defects.
periphery of a pultruded shape.
NOTE—This condition is the result of
an interruption in the normal
continuous pulling operation.

Wire Brush Surface A roughness due to fibers protruding None Permitted if protruding fibers are encapsulated with resin. They shall not create a
above the surface of the pultruded sharp feeling. If so, repair.
part.

Wrinkle Depression An undulation or series of undulations None Depressions are permitted if depth is Depressions are permitted if less than
or waves on the surface of the less than 10 % of shape thickness (6 15 % of shape thickness, (9 mm) in
pultruded part. mm) in width and frequency of width and frequency of occurrence
Note—This condition can occur in occurrence per 3 m of pultruded per 3 m of pultruded length not over
either the lengthwise or crosswise length not over 4 continuous or 8 6 continuous or 10 intermittent
direction of the pultrusion and is intermittent depressions. Wrinkle-like depressions. Wave-like wrinkles on
caused by reinforcement shifting and waves shall be 3 mm wide or less. flange tips shall be 4.5 mm or less
crowding (see folded reinforcement).
Wrinkles affect the flatness of the
surface.

SUMMARY OF CHANGES

Committee D20 has identified the location of selected changes to this standard since the last issue (D4385 - 08)
that may impact the use of this standard. (April 1, 2010)

(1) Changed “grades of product quality” to “the three of four (14) Added to level III of Discoloration: “Continuous discol-
grades of product quality identified herein” in 1.3. orations caused by a veil overlap are permitted. Mat discolor-
(2) Adeed or by ASTM D3917 to 3.2 ations are not rejectable”
(3) Changed 5 mm to 4.7 mm in 3.3 (15) Added to level III of Exposed Rovings: “…without
(4) Added “of critical area(s) to 3.4.3 rejection. Connection areas can have exposed rovings.”
(5) Changed “dimensions are surface dimensions” to “the (16) Eliminated Glassiness as redundant to other items in this
dimensions in this document are surface dimensions” in 4.1. specifications.
(6) Changed “or beyond” to “or is beyond” in 4.5 (17) Added “and mechanical” to grooving.
(7) Eliminated the note for Black Marking. (18) Folded reinforcement. Changed “chiefly visible” to “vis-
(8) Added “and all product test requirements are satisfied” for
ible”. Removed the sentence beginning with “Such
Black Marking.
reinforcement…” An editioral change was made to level III.
(9) Changed 80 % to 40 % for Blister width. Changed max
width to 7 cm from 13 cm for Blister. Eliminated “if less than (19) For Internal Shrinkage Cracks. Added “and which termi-
4 per 650 square mm from Blister. nate in the off-axis reinforcement.” Added “without numerical
(10) Eliminated the reference to “popcorn” blister in the note limit” in the level III classification. Deleted the last sentence of
on Blister. the note.
(11) Eliminate “Blooming, Fiber” as this is a durability and not (20) Added to Porosity, internal in level III: “Shapes exceeding
a manufacturing issue. the limits can be accepted if the properties including water
(12) Editorial for Crack; eliminate “occurs internally” from the absorption are satisified.”
definition. (21) Deleted Reinfocement Rich because it is redundant to
(13) Added “causing a localized thickness change exceeding other items in this specification.
13 mm (.005 in.) for the definition of Delamination. (22) Changed “Wrinkle-like waves” to Wave-like wrinkles.”

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